Enhanced roofing system

ABSTRACT

A roof system includes a roof deck, a weighted cover board disposed upwardly adjacent the roof deck and a plurality of fasteners coupling the weighted cover board to the roof deck.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser.No. 62/673,570 filed May 18, 2018, which is incorporated herein byreference in its entirety.

BACKGROUND

Exemplary embodiments of the invention relate to a roof system, and moreparticularly, to a roof system suitable to meet the 2016 Wind Codeapplicable to roofing systems.

Roof structures have been made for millennia ranging from simple lean-tothatched arrangements to more modern buildings having multiple layers ofroofing materials, fire barriers, vapor barriers, air retarders, rigidroof insulations, cover boards, slipsheets and waterproofing membranesall designed to work together to keep the elements away from occupantsof the building. Roof structures continue to be improved because each ofthe systems currently available has drawbacks and improvements aretherefore desirable. Typical problems with roof structures relate towind uplift resistance, energy efficiency with insulations for heat andcold resistance to maintain internal building temperature, as well astime and effort required to install the roof system. Due to changes inthe code regarding wind uplift resistance, some conventional roofsystems are not capable of meeting these increase requirements.

BRIEF SUMMARY OF THE INVENTION

According to one embodiment of the disclosure, a roof system includes aroof deck, a weighted cover board disposed upwardly adjacent the roofdeck and a plurality of fasteners coupling the weighted cover board tothe roof deck.

According to another embodiment, a method of forming a roof system sinstalling a roof deck, positioning a weighted cover board upwardlyadjacent a roof deck, and fastening the weighted cover board to the roofdeck with a plurality of fasteners.

According to another embodiment, a roof system includes a roof deck anda layer of weighted cover board disposed upwardly adjacent the roofdeck. The layer of weighted cover board includes a plurality of panelsof weighted cover board and a plurality of joints is formed betweenadjacent panels of weighted cover board. A sealant is arranged at theplurality of joints formed between adjacent panels of weighted coverboard.

According to yet another embodiment, a method of forming a roof systemincludes installing a roof deck, positioning a layer of weighted coverboard upwardly adjacent a roof deck. The layer of weighted cover boardincludes a plurality of panels of weighted cover board such that aplurality of joints is formed between adjacent panels of weighted coverboard. The method additionally includes sealing the plurality of jointsformed between adjacent panels of the weighted cover board.

According to another embodiment, a roof system includes a roof deck, alayer of weighted cover board disposed upwardly adjacent the roof deck,and an adhesive arranged at an upper surface of the roof deck forcoupling the layer of weighted cover board to the roof deck.

According to another embodiment, a method of forming a roof systemincludes installing a roof deck. The roof deck includes a plurality offluted panels arranged in an overlapping relationship and each of theplurality of fluted panels has at least one upper flute and at least onelower flute. The method additionally includes applying an adhesive to atleast one of the roof deck and a layer of weighted cover board andpositioning the layer of weighted cover board upwardly adjacent the roofdeck such that the adhesive couples the layer of weighted cover board tothe roof deck.

According to another embodiment, a roof system includes a roof deck, aweighted cover board disposed upwardly adjacent the roof deck, and asealant assembly applied to the roof deck such that the roof deck formsan air barrier.

According to yet another embodiment, a method of forming a roof systemincludes installing a roof deck. The roof deck includes a plurality offluted panels arranged in an overlapping and/or nested relationship.Each of the plurality of fluted panels has at least one upper flute andat least one lower flute. The method further includes positioning alayer of weighted cover board upwardly adjacent the roof deck andseating the roof deck to form an air barrier.

According to another embodiment, a roof system includes a roof deck, afirst layer of weighted cover board disposed upwardly adjacent the roofdeck, one or more layers of insulation positioned upwardly adjacent saidfirst layer of weighted cover board, and a second layer of weightedcover board disposed upwardly adjacent the one or more layers ofinsulation. The second layer of weighted cover board comprises aplurality of panels of weighted cover board such that a plurality ofjoints is formed between adjacent panels of the weighted cover board. Asealant is arranged at the plurality of joints formed between adjacentpanels of the second layer of weighted cover board.

According to yet another embodiment, a method of forming a roof systemincludes installing a roof deck, positioning a first layer of weightedcover board upwardly adjacent the roof deck, positioning one or morelayers of insulation in overlapping arrangement with the first layer ofweighted cover board, positioning a second layer of weighted cover boardupwardly adjacent the one or more layers of insulation, the second layerof weighted cover board comprising a plurality of panels of weightedcover board such that a plurality of joints are formed between adjacentpanels of the second layer of weighted cover board, and sealing theplurality of joints of the second layer of weighted cover board.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter, which is regarded as the invention, is particularlypointed out and distinctly claimed in the claims at the conclusion ofthe specification. The foregoing and other features, and advantages ofthe invention are apparent from the following detailed description takenin conjunction with the accompanying drawings in which:

FIG. 1 is a cross-sectional view of a roof system according to anembodiment;

FIG. 2 is a cross-sectional view of another roof system according to anembodiment;

FIG. 3 is a cross-sectional view of another roof system according to anembodiment;

FIG. 4 is a cross-sectional view of another roof system according to anembodiment;

FIG. 5 is a cross-sectional view of another roof system according to anembodiment;

FIG. 6 is a cross-sectional view of another roof system according to anembodiment; and

FIG. 7 is a cross-sectional view of another roof system according to anembodiment.

The detailed description explains embodiments of the invention, togetherwith advantages and features, by way of example with reference to thedrawings.

DETAILED DESCRIPTION

Referring now to FIG. 1, an example of a roof system 10 as taught hereinis illustrated. The roof system 10 includes a truss 12 or anotherstructural support. The truss 12 is suitably supported by a buildingstructure (not shown) that is not relevant to the roof system disclosedherein, and therefore need not be described or illustrated. A roof deck14, such as a corrugated metal deck for example, is arranged upwardlyadjacent the truss 12, and is therefore supported by the truss 12. Itshould be understood that other types of decks, such as wooden,composite plank, precast, and poured in place decks are also within thescope of the disclosure. In the illustrated, non-limiting embodiment,the deck 14 is constructed from multiple corrugated panels, each havinga plurality of flutes including an upper flute and a lower flute.Adjacent panels of the deck 14 are configured to “nest” with one anotherby a distance of about 2-4 inches along a direction parallel to thelongitudinal axis defined by each flute. Alternatively, or in addition,one or more flutes arranged at the ends of adjacent panels are in anoverlapping arrangement as shown in the FIGS. The deck 14, as describedherein, extends over the entire roof structure of the building.

In the illustrated, non-limiting embodiment, a layer of weighted coverboard 18 is positioned directly adjacent an upper surface of the deck14. The weighted cover board 18 has a substantially uniform weightacross the entire roofing system, regardless of its position relative toa perimeter thereof. The weight of the cover board 18 is generallybetween about 1 pound per square foot and about 25 pounds per squarefoot. The weight of the cover board 18 may vary in part based on thethickness of the cover board, and is selected based on the intendedapplication of the cover board. The weighted cover board 18 mayadditionally have properties such that it holds its shape, even whilebeing pulled non-uniformly by attachments to the roof and buildingstructures for example. Because of this tendency to retain its shape,the cover board 18 evenly distributes loads applied thereto to minimizelocalized stress levels.

The cover board 18 generally comprises one or more of plywood, orientedstrand board, gypsum, rigid fiber board, cement board or otherrelatively heavy solid board material for example. In an embodiment, thecover board 18 is Kelly Green Board manufactured by Kelly GreenProducts. In such embodiments, the cover board 18 is formed from amoisture and mold resistant material. In an embodiment, the compositematerial is formed entirely from recycled materials, such as beveragecartons and cups for example. Because Kelly Green Board is formedwithout the use of formaldehyde glues, or other hazardous chemicals, thecover board 18 is free from volatile organic compounds. In anembodiment, the cover board 18 may have fire-resistant properties suchthat the cover board 18 may function as a fire barrier, and in someembodiments may be self-extinguishing. Alternatively, or in addition,the cover board 18 may be water-resistant or waterproof.

The layer of weighted cover board 18 typically comprises a plurality ofsubstantially identical panels laid adjacent one another to form aplurality of joints 20. However, embodiments comprising a single panelof weighted cover board are also contemplated herein. With reference toFIG. 1, in the illustrated, non-limiting embodiment, the one or morepanels of cover board 18 are “loosely laid” over the upper surface ofthe deck 14. The term “loosely laid” is understood by a person havingordinary skill in the art to described embodiments where the cover board18 is not adhered or mechanically affixed to the adjacent surface of thedeck 14.

In addition, a sealant 22 is positioned in the joints 20 formed betweenadjacent panels of the cover board 18. The sealant 22 may be anysuitable type of sealant, including a silicone roof coating for example.In an embodiment, the sealant 22 blocks the flow of air through thejoints 20 between adjacent panels of cover board 18. Because the coverboard 18 is formed from an impervious material through which air cannotflow, together the layer of cover board 18 and the sealant 22 positionedin the joints 20 form an air barrier. In some embodiments, a roof system10, such as the one illustrated and described in FIG. 1 is operable as a“temporary roof structure” during completion of the roof system 10.

With reference now to FIG. 2, the roof system 10 may further comprise aplurality of fasteners 24 to mechanically fasten the plurality of panelsof cover board 18 to the roof system. The plurality of fasteners 24, maybe used as an alternative to, or in addition to the sealant describedwith reference to FIG. 1. In an embodiment, at least one of theplurality of fasteners 24 is sized to extend through the cover board 18to the deck 14. In another embodiment, at least one of the plurality offasteners 24 is configured to extend through the cover board and thedeck 14 to the truss 12. The fasteners 24 may be positioned to alignwith and extend through the upper flutes 16 of the deck 14 and may bepositioned at intervals, such as every six inches on center for examplealong the longitudinal axis defined by the upper flutes.

In an embodiment, the fasteners 24 are self-drilling or self-tappingscrews, such as a TEK® screws for example. The roof system 10 includinga plurality of fasteners 24 provides a load per square foot of upliftresistance of about 200 lb/sq. ft. In embodiments where the cover board18 is Kelly Green Board, the heat generated during installation of thefasteners 24 causes the material of the cover board 18 adjacent eachfastener hole to melt. The melted material then flows toward the openingand the fastener 24 positioned therein. As a result, the Kelly GreenBoard can be considered to have “self-sealing” qualities.

A washer 26, such as a fender washer for example, may, but need not be,positioned between the head of each fastener 24 and the adjacent surfaceof the cover board 18 to increase the allowable load per square foot inuplift resistance up to about 5000 lb/sq. ft. It should be understoodthat the illustrated and described roof system 10 may be used wheninstalling a new roof or during reroofing operations. For reroofing, theexisting roofing system is stripped down to the roof deck and the roofdeck is structurally refastened with another deck, in this instance thecover board.

With reference now to FIG. 3, another embodiment of a roof system 10 isillustrated. Similar to the system of FIGS. 1 and 2, the system 10includes a truss 12, a deck 14 layered adjacent an upper surface of thetruss 12, and a layer of weighted cover board 18 positioned upwardlyadjacent the deck 14. In the illustrated, non-limiting embodiment, anadhesive material 28 is positioned between the deck 14 and the weightedcover board 18 to couple the cover board 18 to the deck 14. As shown,the adhesive 28 may be positioned on an upper surface of each of theupper flutes 16 of the deck 14 configured to contact the cover board 18.The adhesive 28 may be a sealant, such as a silicone sealant forexample. Use of a silicone sealant provides the added benefits of beinginflammable and not being affected by cold temperatures. However itshould be understood that other materials, such as a urethane adhesiveor any suitable alternative material are also within the scope of thedisclosure. The adhesive 28 between the cover board 18 and the deck 14provides structural shear and diaphragm forces resulting in increasedwind uplift resistance, and therefore greater loading capability.

The adhesive 28 may be used as an alternative to, or in addition to thesealant 22 and/or fasteners 24, illustrated and described in FIGS. 1 and2. In an embodiment, illustrated in FIG. 4, the roof system 10additionally includes a sealant 22 positioned within the joints 20formed between adjacent panels of the cover board 18. The sealant 22positioned between the joints 20 of the cover board 18 may be the samematerial as the adhesive 28 used to adhere the panels of cover board 18to the deck 14. However, embodiments where the sealant 22 is a differentmaterial than the adhesive 28 are also contemplated herein. Further,embodiments where the joints 20 do not include a sealant 22 are alsocontemplated herein.

In embodiments where the cover board 18 is coupled to the deck 14 via anadhesive 28, fasteners extending through the cover board 18, deck 14,and truss 12 are not required. However, in some embodiments, such asshown in FIG. 4 for example, a plurality of fasteners 24 mayadditionally be used to couple the cover board 18 to the deck 14, and insome embodiments the truss 12, for added strength and wind upliftresistance. Any of the roof systems 10, illustrated and described inFIGS. 1-4, can function as a “temporary roof structure” duringcompletion of the roof system 10. Further, such roof systems 10 may becreated during a re-roofing operation.

With reference now to FIG. 5, the deck 14 of the roof system 10 may besealed causing the deck 14 to act as an air barrier. To seal the deck14, a sealant 30, such as the same sealant or a different sealant thanthat used to seal the joints 20 between adjacent panels of cover board18, is positioned at the joints formed between adjacent pieces of deck14. In some embodiments, the sealant 30 is additionally installedadjacent the holes formed by installation of the fasteners 24.Positioned in overlapping arrangement with the sealant 30 is a piece offabric 32. Although the fabric 32 is illustrated as being positionedupwardly adjacent the sealant 30, embodiments where the fabric 32 isarranged directly adjacent the deck 14 and the sealant 30 is appliedthereto are also contemplated herein. In some embodiments, insulation(not shown) may be arranged at the overlapping flutes between the deck14 and the weighted cover board 18.

The sealant 30 and fabric 32 may be used in addition to or as an to anyof the previous embodiments described herein. Accordingly, although thesystem of FIG. 5 is illustrated as including a sealant 22 between thejoints 20 of the cover board 18, an adhesive 28 between the cover board18 and the deck 14, and a plurality of fasteners 24, the sealant 30 andfabric 32 may be applied to any of the previous roof systems 10described herein to form an air barrier.

Further, each of the roof systems 10 illustrated in FIGS. 1-5, isdescribed in its simplest form. It should therefore be understood thateach of the systems 10 may additionally include other layers commonlyused in conventional roofing systems. For example, one or more layers ofinsulation 40 may be positioned above the upper surface of the weightedcover board 18, as shown in FIG. 6. The insulation 40 may be “looselaid” and therefore is not mechanically fastened to the adjacentweighted cover board 18. The insulation 40 may be formed frompolyisocyanurate or expanded or extruded polystyrene as well as otherinsulating materials common to the roofing industry. Although two layersof insulation 40 is illustrated in the FIG., embodiments including asingle layer of insulation 40 or more than two stacked layers ofinsulation 32 are within the scope of the invention. In embodimentshaving more than one layer of insulation 40, adjacent layers may belocally attached to one another, such as with an adhesive, liquid nail,or spray foam for example.

Alternatively, or in addition, the roof system 10 may include awaterproofing membrane 42 positioned as the upper most surface of therood system 10. The membrane 42 may be made of ethylene propylene dienemonomer (EPDM), chlorosulfonated polyethylene (CSPE), polyvinyl chloride(PVC) or other similar roof waterproofing single ply membranes. Thesystem may additionally include other layers commonly used inconventional roofing systems. For example, a vapor barrier adhesive (notshown) may be positioned between the deck 14 and the cover board 18 orbetween the cover board 18 and the adjacent insulation 40 to minimizethe diffusion of moisture into the building through the roof system. Inaddition, flashing, or thin pieces of generally impervious material, maybe installed, over a portion or all of the waterproofing membrane toform a weather resistant barrier and prevent water from passing into theroof system 10.

In the non-limiting embodiment illustrated in FIG. 6, alternatively, orin addition to the sealant 30 and fabric 32 arranged at the overlappingflutes 16, the adhesive 28, the sealant 22, and/or around the fasteners24, the system 10 includes a shaped component 44 to form an air barrieradjacent the deck 14. The shaped component 44 has a first end 46positioned generally adjacent the deck 14, such as between the deck 14and the cover board 18 for example. In an embodiment, the shapedcomponent 44 is a bent piece of sheet metal. The shaped component 44 maybe J-shaped such that the first end 46 covers the substantial entiretyof the upper surface of the deck 14. In another embodiment, the shapedcomponent 44 may be C or U-shaped such that the first end 46 covers onlya portion of the upper surface of the deck 14. The second end 48 of theshaped component 44 is arranged generally parallel to the first end 46and is separated therefrom by one or more layers of an additionalmaterial, including but not limited to insulation 40, as shown in FIG.6. In an embodiment, a protective coating or material 50, such as butylgum rubber or other suitable materials for example, is applied to aninterior surface of the shaped component 44.

A waterproofing membrane 42 may be used to seal the second end 48 of theshaped component 44 to the top of the roof structure. Particularly inembodiments where the deck 14 or the shaped component 44 has a coatingapplied thereto, inclusion of the waterproofing membrane 42, incombination with the shaped component 44, forms a protective air andwater barrier that functions to encapsulate the insulation 40 within theroof system 10.

With reference now to FIG. 7, regardless of the configuration of theweighted cover board 18 and whether it includes sealant, or is connectedto the deck 14 with adhesive 28, or fasteners 24, in an embodiment, asecondary layer of weighted cover board 52 may be positioned upwardlyadjacent the one or more layers of insulation 40. A person havingordinary skill in the roofing art will recognize that this applicationdoes not require the use of an adhesive material between the insulation40 and the weighted cover board 52. Similar to the weighted cover aboard18 adjacent the deck 14 as described with respect to FIG. 1, the joints54 formed in the layer of cover board 52 disposed vertically above theinsulation 40 may be sealed with a sealant 56. The sealant 56 may be anysuitable type of sealant, including a silicon roof coating for example.In an embodiment, the sealant 56 blocks the flow of air through thejoints 54 between adjacent pieces of cover board 52. In embodimentswhere the cover board 52 is formed from a waterproof material, such asKelly Green Board for example, sealing the joints 54 additionally blocksthe flow of water into the roof system 10.

While the invention has been described in detail in connection with onlya limited number of embodiments, it should be readily understood thatthe invention is not limited to such disclosed embodiments. Rather, theinvention can be modified to incorporate any number of variations,alterations, substitutions or equivalent arrangements not heretoforedescribed, but which are commensurate with the spirit and scope of theinvention. Additionally, while various embodiments of the invention havebeen described, it is to be understood that aspects of the invention mayinclude only some of the described embodiments. Accordingly, theinvention is not to be seen as limited by the foregoing description, butis only limited by the scope of the appended claims.

What is claimed is:
 1. A roof system, comprising: a roof deck; a firstlayer of weighted cover board disposed upwardly adjacent the roof deck;one or more layers of insulation positioned upwardly adjacent said firstlayer of weighted cover board; a second layer of weighted cover boarddisposed upwardly adjacent the one or more layers of insulation, whereinthe second layer of weighted cover board comprises a plurality of panelsof weighted cover board such that a plurality of joints are formedbetween adjacent panels of the weighted cover board; and a sealantarranged at the plurality of joints formed between adjacent panels ofthe second layer of weighted cover board.
 2. The roof system of claim 1,wherein the second layer of weighted cover board and the sealant form awaterproof layer.
 3. The roof system of claim 1, wherein the sealant isa silicone roof coating.
 4. The roof system of claim 1, wherein thesecond layer of weighted cover board is loosely laid over theinsulation.
 5. The roof system of claim 1, further comprising aplurality of fasteners that couple the first layer of weighted coverboard to the roof deck.
 6. The roof system of claim 5, furthercomprising a plurality of washers, the plurality of washers beingpositioned between the plurality of fasteners and the first layer ofweighted cover board.
 7. The roof system of claim 1, further comprisingan adhesive arranged at an upper surface of the roof deck for couplingthe first layer of weighted cover board to the roof deck.
 8. The roofsystem of claim 1, wherein the first layer of weighted cover boardcomprises a plurality of panels of weighted cover board such that aplurality of joints are formed between adjacent panels of the weightedcover board, the roof system further comprising a second sealantarranged at the plurality of joints formed between adjacent panels ofthe first layer of weighted cover board.
 9. The roof system of claim 8,wherein h sealant and the second sealant are the same material.
 10. Theroof system of claim 8, wherein the sealant and the second sealant aredifferent materials.
 11. The roof system of claim 1, wherein at leastone of the first layer of weighted cover board and the second layer ofweighted cover board comprises Kelly Green Board.
 12. A method offorming a roof system comprising: installing a roof deck; positioning afirst layer of weighted cover board upwardly adjacent the roof deck;positioning one or more layers of insulation in overlapping arrangementwith the first layer of weighted cover board; positioning a second layerof weighted cover board upwardly adjacent the one or more layers ofinsulation, the second layer of weighted cover board comprising aplurality of panels of weighted cover board such that a plurality ofjoints are formed between adjacent panels of the second layer ofweighted cover board; and sealing the plurality of joints of the secondlayer of weighted cover board.
 13. The method of claim 12, whereinsealing the plurality of joints of the second layer of weighted coverboard comprises applying a sealant to each of the plurality of joints.14. The method of claim 13, wherein the sealant comprises a siliconeroof coating.
 15. The method of claim 12, wherein the second layer ofweighted cover board is loosely adjacent the one or more layers ofinsulation.
 16. The method of claim 12, further comprising applying anadhesive at an interface between the second layer of weighted coverboard and the one or more layers of insulation.
 17. The method of claim12, further comprising fastening the first layer of weighted cover boardto the roof deck with a plurality of fasteners.
 18. The method of claim17, further comprising positioning a plurality of washers between theplurality of fasteners and the first layer of weighted cover board. 19.The method of claim 12, wherein the first layer of weighted cover boardcomprises a plurality of panels of weighted cover board such that aplurality of joints are formed between adjacent panels of the firstlayer of weighted cover board, the method further comprising sealing theplurality of joints of the first layer of weighted cover board.
 20. Themethod of claim 12, further comprising applying an adhesive at aninterface between the first layer of weighted cover board and the roofdeck.